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EP3500769B1 - Method for machining the interior of a brake caliper of a disc brake - Google Patents

Method for machining the interior of a brake caliper of a disc brake Download PDF

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Publication number
EP3500769B1
EP3500769B1 EP17811185.2A EP17811185A EP3500769B1 EP 3500769 B1 EP3500769 B1 EP 3500769B1 EP 17811185 A EP17811185 A EP 17811185A EP 3500769 B1 EP3500769 B1 EP 3500769B1
Authority
EP
European Patent Office
Prior art keywords
tool
brake
opening
caliper
support surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP17811185.2A
Other languages
German (de)
French (fr)
Other versions
EP3500769A1 (en
EP3500769B2 (en
Inventor
Alexander Flocke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BPW Bergische Achsen KG
Original Assignee
BPW Bergische Achsen KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by BPW Bergische Achsen KG filed Critical BPW Bergische Achsen KG
Publication of EP3500769A1 publication Critical patent/EP3500769A1/en
Publication of EP3500769B1 publication Critical patent/EP3500769B1/en
Application granted granted Critical
Publication of EP3500769B2 publication Critical patent/EP3500769B2/en
Active legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/22—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/22—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads
    • F16D55/224—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members
    • F16D55/225—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members the braking members being brake pads
    • F16D55/226—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members the braking members being brake pads in which the common actuating member is moved axially, e.g. floating caliper disc brakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/005—Components of axially engaging brakes not otherwise provided for
    • F16D65/0068—Brake calipers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/14—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position
    • F16D65/16—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake
    • F16D65/18—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2215/00—Details of workpieces
    • B23C2215/08—Automotive parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2270/00—Details of milling machines, milling processes or milling tools not otherwise provided for
    • B23C2270/18—Milling internal areas of components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q3/00—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine
    • B23Q3/155—Arrangements for automatic insertion or removal of tools, e.g. combined with manual handling
    • B23Q3/1552—Arrangements for automatic insertion or removal of tools, e.g. combined with manual handling parts of devices for automatically inserting or removing tools
    • B23Q3/1554—Transfer mechanisms, e.g. tool gripping arms; Drive mechanisms therefore
    • B23Q2003/155404—Transfer mechanisms, e.g. tool gripping arms; Drive mechanisms therefore the transfer mechanism comprising a single gripper
    • B23Q2003/155407—Transfer mechanisms, e.g. tool gripping arms; Drive mechanisms therefore the transfer mechanism comprising a single gripper linearly movable
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D2055/0004—Parts or details of disc brakes
    • F16D2055/0016—Brake calipers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D2055/0004—Parts or details of disc brakes
    • F16D2055/0016—Brake calipers
    • F16D2055/002—Brake calipers assembled from a plurality of parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2121/00—Type of actuator operation force
    • F16D2121/14—Mechanical
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2125/00—Components of actuators
    • F16D2125/18—Mechanical mechanisms
    • F16D2125/20—Mechanical mechanisms converting rotation to linear movement or vice versa
    • F16D2125/22—Mechanical mechanisms converting rotation to linear movement or vice versa acting transversely to the axis of rotation
    • F16D2125/28—Cams; Levers with cams
    • F16D2125/32—Cams; Levers with cams acting on one cam follower
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/003—Chip removing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting
    • Y10T29/49989—Followed by cutting or removing material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49995—Shaping one-piece blank by removing material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/30—Milling
    • Y10T409/303752—Process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/30—Milling
    • Y10T409/304424—Means for internal milling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T483/00—Tool changing
    • Y10T483/10—Process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T483/00—Tool changing
    • Y10T483/17—Tool changing including machine tool or component
    • Y10T483/1733—Rotary spindle machine tool [e.g., milling machine, boring, machine, grinding machine, etc.]
    • Y10T483/1736—Tool having specific mounting or work treating feature

Definitions

  • the invention relates to a method for internal machining of a brake caliper of a disc brake with the features of the preamble of claim 1.
  • a brake caliper is composed of a caliper section on one side of the brake disc of the disc brake, a caliper section on the other side of the brake disc and one of the two Bridge section connecting the caliper sections, which bridges the outside of the brake disk when the disk brake is ready for operation and provides a free space into which the brake disk of the disk brake projects at least partially.
  • At least one of the two caliper sections has a cavity which has an opening to the free space, a brake application device being accommodated in the cavity.
  • brake calipers are known both in one-piece design in the sense of one piece, and in a multi-piece design.
  • the multi-part design basically has the advantage of easier accessibility of individual brake caliper areas for machining, e.g. B. by means of drilling or milling tools.
  • cavities of the brake caliper can also be reached relatively easily in terms of production technology, as can the connection surfaces on which the individual caliper parts are subsequently connected to one another, for. B. by appropriate screw connections.
  • this connection is also disadvantageous in that the saddle parts have to be connected to one another in a separate assembly process.
  • the openings have an additional function. They are not only work or assembly openings, but also serve as a support bearing for a bolt, which is part of the brake application device.
  • the one-piece brake caliper after the EP 1 881 472 A1 is provided for the mechanical machining of a hydraulic actuating cylinder with a machining opening arranged in alignment with the actuating cylinder. This is designed in the manner of a recess and is located in the opposite caliper section of the brake caliper, that is to say on the other side of the brake disc.
  • Another method for machining the inner surfaces in a one-piece brake caliper is from the EP 1 160 480 A2 known.
  • the housing of the brake caliper is provided with an opening in the back which allows a tool to be passed through during the manufacture of the brake caliper.
  • the tool works in the rear grip, ie it is guided, including its tool holder, from behind into the interior of the brake caliper, but the milling cutter attached to the tool works in the opposite direction. After completing this work, the work opening is closed by a plate attached from the inside.
  • the invention has for its object to provide a method for the inner machining of a caliper of a disc brake, which also The tight space that is typical for machining a one-piece brake caliper enables high-precision machining of the support surfaces inside the brake caliper.
  • a tool is moved in such a way from the outside of the brake caliper in the cavity, that the tool is guided through another opening than the mounting opening into the cavity for the processing of the supporting surface.
  • the tool passes through an opening in the brake caliper cavity through which the associated tool holder would not fit. Instead, the tool, on the one hand, and the tool holder, on the other hand, reach the area of the brake caliper in different ways in which the inside of the caliper is subsequently machined. Through that opening, which is not the assembly opening, only the tool itself gets into the cavity, that is, into the interior of the brake caliper.
  • the tool holder on the other hand, is moved in another way into a position relative to the position of the brake caliper that is suitable for the subsequent machining of the support surface. Only then is the tool holder equipped with the tool fed through the additional opening, so that the machining of the support surface can then begin.
  • the tool can be returned through the same opening, i.e. through the same opening. H. through the additional opening, out of the inside of the brake caliper.
  • the processing tool which, for. B. can be a milling head or a drilling head, in other ways in the area of the inner machining of the brake caliper than the associated tool holder, the sequence of movements, insofar as this is relevant for manufacturing precision, is simple. Additional movement options associated with additional bearing play are eliminated, which enables high-precision machining of the support surfaces inside the brake caliper.
  • the opening through which the tool is guided into the cavity of the brake caliper represents an additional opening of the brake caliper. However, it can be located in a location, for example in the rear wall of the caliper, where such an opening can have a second functionality and in particular a functionality that is important for the later operation of the brake. In particular, how this can be done in and of itself DE 195 07 308 A1 is known to serve such an opening to accommodate elements of a reset device. Because disc brakes are usually with one Provide adjusting device, which adjusts or readjusted the air play of the brake, which changes over time. If the two brake linings of the disc brake are worn, they must be replaced, and at the same time the adjustment device must be returned to its starting position, which is done by means of the reset device mentioned.
  • the tool is first passed through the opening and then transferred to the tool holder, which can also be provided with a rotary drive for the tool, for. B. by coupling with the tool holder.
  • the tool is preferably transferred to the tool holder by a movement in the longitudinal direction of the opening.
  • the tool holder projects at least partially into the space between the two saddle sections during the transfer of the tool.
  • a further embodiment of the method is characterized by the steps of transferring the tool to the tool holder and moving the tool away after its decoupling from the tool holder
  • the brake caliper is preferably fixedly positioned in a workpiece holder, which can be moved in at least two axes of movement relative to a stationary machine frame, and the workpiece holder is moved along one of these axes of movement during machining of the support surface.
  • the tool holder When using such a movable workpiece holder, the tool holder itself can be arranged in a stationary and thus immovable manner on the machine frame. In this way, it works without bearing play, which leads to high precision when machining the support surface.
  • first a first support surface and then a second support surface aligned with it are machined one after the other, whereby the opening is between the support surfaces.
  • This division of the support surfaces makes it possible to design a brake lever, which forms a central element of the application device, in the form of a fork by being supported with one first leg against one and with a second leg against the other support surface.
  • the support surface or each support surface is machined in an H shape to form two wider support surface sections and a narrower central section arranged between them.
  • the support surface or each support surface is machined as a partially cylindrical groove.
  • a bearing shell designed as a partially cylindrical groove is preferably placed on the support surface machined in this way, on the inside of which the brake lever can be supported when the disc brake is mounted.
  • a brake caliper 1 of a disc brake is shown, the disc brake here being of the type of a compressed air-operated commercial vehicle brake of the sliding caliper or floating caliper type.
  • the brake caliper 1 cast in a single piece is composed of three sections.
  • a first caliper section 11, which is located inside the vehicle when the brake is mounted, is provided in its interior with a cavity 7 which is accessible via a mounting opening 4 and which offers space for a brake application device.
  • a second caliper section 12, which is located outside the vehicle when the brake is mounted, is arranged on the opposite side of the brake disc 2 of the disc brake.
  • the two caliper sections 11, 12 are connected to one another by a bridge section 13, which bridges the brake disc 2 and thereby provides a free space 6 for at least part of the brake disc 2.
  • the brake disc 2 rotates on the axis A.
  • the brake caliper 1 is in one piece insofar as the two caliper sections 11, 12 and the bridge section 13 consist of a single part, preferably by casting them together in cast iron or cast steel.
  • the cavity 7 of the first saddle section 11 is open to the free space 6 of the bridge section 13. This opening serves u. a. as a mounting opening 4 and it is relatively large so that the brake application device can be mounted through it.
  • the opening or assembly opening 4 is closed by a cover 5 after the brake assembly has been completed.
  • a first brake pad is in Fig. 1 to the right of brake disc 2. This on the tension side
  • the brake pad is actuated directly by the brake application device arranged in the cavity 7 of the caliper section 11 and thus pressed against the brake disc 2.
  • the second brake pad is arranged in the second caliper section 12 and takes a fixed position there. It is the brake lining on the reaction side.
  • the task of the brake application device is to amplify the braking forces generated by a force element and to transmit them in the application direction Z, which extends parallel to the axis A of the brake disc 2.
  • Components of the application device include a brake lever 10 pivotably mounted in the caliper section 11 of the brake caliper 1 and a pressure piece 8 working in the direction of the vehicle-side brake lining on the application side.
  • the pressure piece 8 has the shape of a cross-piece extending transversely to the longitudinal direction of the housing. In the middle of the crossbeam 8, this is connected via a thread to a pressure stamp, which is supported against the brake lining of the disc brake on the application side, and can thus act on the brake disc 2.
  • the pivotable brake lever 10 is fork-shaped and consists of a lever arm 14 and a clamping shaft 15 divided into two sections.
  • the clamping shaft 15 is supported against a rear wall 18 of the caliper, which closes the cavity 7 away from the brake disk. This support with respect to the rear wall 18 of the brake caliper takes place by means of a semi-cylindrical, partially cylindrical pivot bearing 16.
  • a bearing shell 21 is arranged between each of the two sections of the application shaft 15 and a support surface 20 formed on the inside of the saddle rear wall 18.
  • the application shaft 15 of the brake lever 10 is supported exclusively on the bearing shell 21, which, like the support surface 20, is designed as a partially cylindrical groove.
  • the application shaft 15 is also partially cylindrical in the contact area with a radius that is equal to the radius on the inside of the curved bearing shell 21.
  • the application shaft 15 is pivotally supported against the pressure piece 8 via a further pivot bearing 17.
  • the pressure piece 8 has a support area in the form of a half-shell.
  • the further pivot bearing 17 can be designed as a roller bearing or as a sliding bearing.
  • the clamping shaft 15 is mounted eccentrically.
  • the pivot bearing 16, which is supported against the bearing shell 21 and thus indirectly against the brake caliper 1 has a pivot axis which is offset in height compared to the pivot axis of the further pivot bearing 17 arranged between the application shaft 15 and the pressure piece 8.
  • the pressure piece 8 therefore moves forward in the application direction Z, as a result of which the brake exerts braking force on the brake pads.
  • the one-piece lever arm 14 is used to turn the application shaft 15. Near its free end, this is provided with a support location against which the power element of the disc brake works.
  • this force element is a pneumatic brake cylinder, which is supplied with compressed air by the compressed air system of the vehicle.
  • the brake lever 10 is generally fork-shaped, since it branches off into two legs, starting from the lever arm 14 arranged on the pivot center line.
  • the first section of the application shaft 15 is located on the first leg, and the second section of the application shaft 15 is located on the second leg.
  • the brake lever 10 has a free space between these two sections. This, as well as the center of the pressure piece 8 provided with a threaded bore, offer sufficient space for an adjusting device which compensates for brake wear occurring over time and corrects the air play of the brake.
  • Components of the adjusting device are u. a. a drive element, an output element that reduces the clearance of the brake, a one-way clutch and an overload element.
  • a spindle serves as the output element of the adjusting device.
  • the adjustment axis is located on the application axis Z and at the same time extends perpendicular to that plane E in which the brake disc 2 extends.
  • the application shaft 15 is divided in two with two shaft sections, there are also at least two support surfaces 20 and two bearing shells 21 for supporting the shaft sections. Of these, there is a support surface 20 with its bearing shell 21 on one side of the application axis Z, and the other support surface 20 with its bearing shell on the other, opposite side of the application axis Z.
  • the opening 25 is formed in the rear wall 18 of the saddle, it offers space for a reset element of a reset device when the brake is ready for operation. Because if the brake pads of the disc brake are worn, they have to be replaced. The adjustment device must then be reset to its starting position, which is done by means of the reset device mentioned.
  • the restoring element of this restoring device is located in the opening 25 of the rear wall 18 of the saddle and, preferably already on the outside of the rear wall 18 of the saddle, is provided with key surfaces to which a corresponding tool can be attached for resetting the brake.
  • the support surfaces 20, on which the braking force of the disc brake rests are each designed as a partially cylindrical groove or shell.
  • the two support surfaces 20 are arranged in mutual alignment.
  • the common reference axis of the radii of their partially cylindrical curvature contours runs parallel to the plane E in which the brake disc extends.
  • each support surface 20 is located on a plateau 26 protruding inward from the saddle rear wall 18 when the saddle is cast.
  • Each support surface 20 is machined in an H-shape and consists of two support surface sections 30 with a larger channel width and an intermediate section 31 with a smaller channel width arranged between them.
  • the narrower central section 31 is caused by two incisions 32, 33, which the plateau 26 has due to the casting process.
  • a wing-shaped tab 34, 35 of the bearing shell 21 projects into each incision 32, 33.
  • Each bearing shell 21 consists of an originally flat metal sheet produced by stamping and shaping.
  • the partially cylindrical outside 29 lies flat against the supporting surface 20, the radius of the partial cylinder being the same.
  • the outer side 29 of the bearing shell 21 extends further in the circumferential direction than the narrow central section 31 of the support surface 20. In this way, the bearing shell 21 is able to move in the circumferential direction on the support surface 20. However, this possibility of movement is limited in both circumferential directions by the End regions of the tabs 34, 35 then abut the molded incisions 32, 33. The tabs 34, 35 therefore serve as stops in order to limit the possibility of movement of the bearing shell 21 in the circumferential direction.
  • the tabs 34, 35 also limit the longitudinal movement of the partially cylindrical bearing shells 21 by the tabs 34, 35 being narrower in the axial direction of the partially cylindrical bearing shell 21 than the cast-in cuts 32, 33.
  • the two support surfaces 20 cannot be produced with the required precision purely by casting. Rather, it is necessary to provide the support surfaces 20 with their exact, partially cylindrical contour by means of a cutting tool and / or a grinding tool. For this purpose, a suitable processing tool must be guided along the support surfaces 20. For example, this can be a rotating milling tool with a part-circular milling head.
  • a suitable processing tool must be guided along the support surfaces 20.
  • this can be a rotating milling tool with a part-circular milling head.
  • the one-piece design of the brake caliper 1 limits the possibilities of placing a processing tool in the cavity 7 of the brake caliper housing in order to machine the two support surfaces 20 there on the plateaus 26.
  • the brake caliper 1 previously cast in one piece, is positioned in one of the workpiece receptacles movable in two or three axes.
  • the workpiece holder then closes the brake caliper 1 in such a way that the tool holder 52, which is arranged in a stationary manner on the machine tool 50, reaches the free space 6 in the bridge section 13 of the brake caliper into which the brake disk 2 at least partially extends when the brake is ready for operation.
  • This infeed is ended when the tool holder of the tool holder 52 is in front of or already in the opening 4 of the brake caliper 1. This state is in Fig. 7a reproduced.
  • Fig. 7b The tool gripper 53 is then activated, on which the tool 55 is provisionally arranged.
  • the tool gripper 53 guides the tool 55 through the rear opening 25 and through the cavity 7 of the brake caliper into the tool holder of the tool holder 52.
  • the tool 55 is locked on the tool holder 52, eg. B. in its chuck.
  • the tool gripper 53 then releases the tool and returns to its waiting position.
  • the tool is now at least predominantly in the cavity 7 of the brake caliper, and the tool holder 52 is predominantly in the free space 6 in front of the cavity 7.
  • the machining and preferably milling of the support surfaces 20 is thus ended, and further internal or external machining of the brake caliper 1 can begin either in the same clamping of the brake caliper 1 or in a different clamping or in another machine tool.
  • the steps of the method can of course also be achieved if the workpiece holder is immovably fixed in the machine tool and the tool holder moves.
  • the combination of a movement of the tool and workpiece holder is also conceivable.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Innenbearbeitung eines Bremssattels einer Scheibenbremse mit den Merkmalen des Oberbegriffs des Patentanspruchs 1. Ein solcher Bremssattel setzt sich zusammen aus einem Sattelabschnitt an der einen Seite der Bremsscheibe der Scheibenbremse, einem Sattelabschnitt an der anderen Seite der Bremsscheibe sowie einem die beiden Sattelabschnitte verbindenden Brückenabschnitt, der bei betriebsfertig montierter Scheibenbremse die Bremsscheibe außen überbrückt und einen Freiraum bereitstellt, in den die Bremsscheibe der Scheibenbremse zumindest teilweise hinein ragt. Zumindest einer der beiden Sattelabschnitte weist einen Hohlraum auf, der zu dem Freiraum hin eine Öffnung aufweist, wobei in dem Hohlraum eine Bremszuspanneinrichtung Platz findet.The invention relates to a method for internal machining of a brake caliper of a disc brake with the features of the preamble of claim 1. Such a brake caliper is composed of a caliper section on one side of the brake disc of the disc brake, a caliper section on the other side of the brake disc and one of the two Bridge section connecting the caliper sections, which bridges the outside of the brake disk when the disk brake is ready for operation and provides a free space into which the brake disk of the disk brake projects at least partially. At least one of the two caliper sections has a cavity which has an opening to the free space, a brake application device being accommodated in the cavity.

Im Stand der Technik sind solche Bremssättel sowohl in einteiliger Bauart im Sinne von einstückig bekannt, als auch in mehrteiliger Bauart. Die mehrteilige Bauart hat grundsätzlich den Vorteil der leichteren Zugänglichkeit einzelner Bremssattelbereiche für die maschinelle Bearbeitung, z. B. mittels Bohr- oder Fräswerkzeugen. Vor allem sind bei mehrteiliger Bauart auch Hohlräume des Bremssattels fertigungstechnisch relativ leicht erreichbar, ebenso die Anschlussflächen, an denen die einzelnen Sattelteile anschließend miteinander verbunden werden, z. B. durch entsprechende Verschraubungen. Diese Verbindung ist aber auch wiederum von Nachteil insofern, als die Sattelteile in einem separaten Montageprozess passgenau miteinander verbunden werden müssen.In the prior art, such brake calipers are known both in one-piece design in the sense of one piece, and in a multi-piece design. The multi-part design basically has the advantage of easier accessibility of individual brake caliper areas for machining, e.g. B. by means of drilling or milling tools. Above all, with a multi-part design, cavities of the brake caliper can also be reached relatively easily in terms of production technology, as can the connection surfaces on which the individual caliper parts are subsequently connected to one another, for. B. by appropriate screw connections. However, this connection is also disadvantageous in that the saddle parts have to be connected to one another in a separate assembly process.

Diese Montage- und Passprobleme treten bei einem einstückigen Bremssattel nicht auf. Jedoch schränkt die einstückige Bauart die Möglichkeiten ein, mittels Bohr- oder Fräswerkzeugen an bestimmte Stellen vor allem in den Hohlräumen des Bremssattelgehäuses zu gelangen. Zu den Flächen im Inneren des Bremssattels, die in jedem Fall maschinell bearbeitet werden müssen, gehören Abstützflächen, auf denen die beim Zuspannen der Bremse wirkenden Kräfte lasten. So sind z. B. Bremssättel für Scheibenbremsen bekannt, bei denen zur Krafterhöhung ein Hebel in dem Hohlraum des Bremssattels angeordnet ist, der sich schwenkbar gegen die entsprechend stabil gestaltete Sattelrückwand des Bremssattels abstützt. An dem Ort dieser Abstützung ist eine spanende Bearbeitung in der Regel unverzichtbar.These assembly and fitting problems do not occur with a one-piece brake caliper. However, the one-piece design limits the possibilities of getting to certain places, especially in the cavities of the brake caliper housing, by means of drilling or milling tools. The surfaces inside the brake caliper, which must be machined in any case, include support surfaces on which the forces acting when the brake is applied bear. So z. B. calipers for disc brakes are known, in which a lever is arranged in the cavity of the brake caliper to increase the force, which is pivotally supported against the correspondingly stable caliper rear wall of the brake caliper. Machining is generally indispensable at the location of this support.

Zur Bearbeitung solcher Abstützflächen ist es aus der DE 195 15 063 C2 bekannt, das Bearbeitungswerkzeug durch eine eigens dafür bestimmte, seitlich am Sattel vorhandene Arbeitsöffnung in das Innere des Sattels einzuführen. Von Nachteil an dieser Arbeitsöffnung ist, dass diese einzig dem Zweck des Hindurchführens des Bearbeitungswerkzeuges dient, die Öffnung hingegen im Betrieb der Scheibenbremse keinerlei Bestimmung hat.For processing such support surfaces, it is from the DE 195 15 063 C2 known to introduce the machining tool into the interior of the saddle through a dedicated work opening on the side of the saddle. The disadvantage of this working opening is that it only serves the purpose of passing the processing tool through, the opening, however, has no purpose in the operation of the disc brake.

Auch bei dem Bremssattel nach der DE 10 2007 001 960 A1 wird ein Werkzeug zur Bearbeitung der Abschnittsflächen durch seitlich in dem Bremssattelgehäuse vorhandene Öffnungen in das Innere des Bremssattels verbracht, um die dort angeordneten Abstützflächen zu bearbeiten. Die Öffnungen haben jedoch eine zusätzliche Funktion. Sie sind nicht nur Arbeits- oder Montageöffnungen, sondern sie dienen auch als Stützlager für einen Bolzen, welcher Bestandteil der Bremszuspanneinrichtung ist.Even with the brake caliper after the DE 10 2007 001 960 A1 a tool for machining the section surfaces is brought into the interior of the brake caliper through openings provided laterally in the brake caliper housing, in order to machine the support surfaces arranged there. However, the openings have an additional function. They are not only work or assembly openings, but also serve as a support bearing for a bolt, which is part of the brake application device.

Der ebenfalls einstückige Bremssattel nach der EP 1 881 472 A1 ist zur mechanischen Bearbeitung eines hydraulischen Betätigungszylinders mit einer in Fluchtung zu dem Betätigungszylinder angeordneten Bearbeitungsöffnung versehen. Diese ist nach Art einer Ausnehmung gestaltet und befindet sich in dem gegenüberliegenden, also auf der anderen Seite der Bremsscheibe angeordneten Sattelabschnitt des Bremssattels.The one-piece brake caliper after the EP 1 881 472 A1 is provided for the mechanical machining of a hydraulic actuating cylinder with a machining opening arranged in alignment with the actuating cylinder. This is designed in the manner of a recess and is located in the opposite caliper section of the brake caliper, that is to say on the other side of the brake disc.

Ein anderes Verfahren zur Bearbeitung der Innenflächen in einem einstückigen Bremssattel ist aus der EP 1 160 480 A2 bekannt. Das Gehäuse des Bremssattels ist rückwertig mit einer Öffnung versehen, die während der Herstellung des Bremssattels die Hindurchführung eines Werkzeuges erlaubt. Das Werkzeug arbeitet dabei im Hintergriff, d. h. es wird einschließlich seines Werkzeugträgers von hinten in das Innere des Bremssattels geführt, jedoch arbeitet der an dem Werkzeug befestigter Fräser in die entgegengesetzte Richtung. Nach Abschluss dieser Arbeiten wird die Arbeitsöffnung durch eine von innen her angesetzte Platte verschlossen.Another method for machining the inner surfaces in a one-piece brake caliper is from the EP 1 160 480 A2 known. The housing of the brake caliper is provided with an opening in the back which allows a tool to be passed through during the manufacture of the brake caliper. The tool works in the rear grip, ie it is guided, including its tool holder, from behind into the interior of the brake caliper, but the milling cutter attached to the tool works in the opposite direction. After completing this work, the work opening is closed by a plate attached from the inside.

Aus der gattungsbildenden EP 2 304 261 B1 ist ein Verfahren zum Herstellen eines einstückigen Bremssattels bekannt, bei dem der Bremssattel ohne eine zusätzliche Arbeitsöffnung auskommt. Die einzige Öffnung ist jene zu der Bremsscheibe hin offene Montageöffnung des Bremssattels, durch die die Zuspannung montierbar ist. Durch diese Öffnung hindurch wird ein Werkzeughalter mit dem daran angeordneten Werkzeug in den Hohlraum des Bremssattels verbracht. Für diese Bewegung ist, da der Werkzeughalter L-förmig und zugleich der Brückenabschnitt in Sattellängsrichtung relativ kurz ist, ein überlagerter Bewegungsablauf notwendig, wobei der Werkzeughalter entweder zunächst eine Drehung um eine virtuell in der Bremsscheibenebene liegende Achse und dann eine gerade Bewegung durchführt, oder der Werkzeughalter zunächst eine schräg angewinkelte und anschließend eine gerade Bewegung durchführt. Überlagerte Bewegungsabläufe erfordern entsprechende Bewegungsoptionen. Mit jeder Bewegungsoption geht jedoch auch ein weiteres Lagerspiel einher, was die Präzision der Bearbeitung der Abstützflächen beeinträchtigen kann.From the generic EP 2 304 261 B1 a method for producing a one-piece brake caliper is known in which the brake caliper does not require an additional working opening. The only opening is the mounting opening of the brake caliper which is open towards the brake disc and through which the tensioning can be mounted. A tool holder with the tool arranged thereon is brought through this opening into the cavity of the brake caliper. For this movement, since the tool holder is L-shaped and at the same time the bridge section in the longitudinal direction of the saddle is relatively short, there is a superimposed sequence of movements Necessary, the tool holder either first rotates about an axis virtually in the plane of the brake disc and then executes a straight movement, or the tool holder first performs an obliquely angled and then a straight movement. Superimposed motion sequences require corresponding motion options. With every movement option, however, there is an additional bearing play, which can impair the precision of the machining of the support surfaces.

Daher liegt der Erfindung die Aufgabe zugrunde, ein Verfahren für die Innenbearbeitung eines Bremssattels einer Scheibenbremse zu schaffen, welches auch bei den für die Bearbeitung eines einstückigen Bremssattels typischen, engen Platzverhältnissen eine hochpräzise Bearbeitung der Abstützflächen innen im Bremssattel ermöglicht.Therefore, the invention has for its object to provide a method for the inner machining of a caliper of a disc brake, which also The tight space that is typical for machining a one-piece brake caliper enables high-precision machining of the support surfaces inside the brake caliper.

Zur Lösung dieser Aufgabe wird zur Bearbeitung der Abstützfläche ein Werkzeug in der Weise von außerhalb des Bremssattels in den Hohlraum verbracht, dass das Werkzeug durch eine andere Öffnung als die Montageöffnung hindurch in den Hohlraum geführt wird.To achieve this object, a tool is moved in such a way from the outside of the brake caliper in the cavity, that the tool is guided through another opening than the mounting opening into the cavity for the processing of the supporting surface.

Bei dieser Lösung gelangt das Werkzeug durch eine Öffnung in den Hohlraum des Bremssattels, durch die der zugehörige Werkzeughalter nicht hindurch passen würde. Stattdessen gelangen das Werkzeug einerseits und der Werkzeughalter andererseits auf unterschiedlichen Wegen in jenen Bereich des Bremssattels, in dem anschließend die Innenbearbeitung des Sattels erfolgt. Durch jene Öffnung hindurch, welche nicht die Montageöffnung ist, gelangt ausschließlich das Werkzeug selbst in den Hohlraum, also in das Innere des Bremssattels. Der Werkzeughalter hingegen wird auf andere Weise in eine für das anschließende Bearbeiten der Abstützfläche geeignete Position relativ zu der Position des Bremssattels verbracht. Erst dann wird der Werkzeughalter mit dem durch die zusätzliche Öffnung zugeführten Werkzeug bestückt, so dass anschließend das Bearbeiten der Abstützfläche beginnen kann.In this solution, the tool passes through an opening in the brake caliper cavity through which the associated tool holder would not fit. Instead, the tool, on the one hand, and the tool holder, on the other hand, reach the area of the brake caliper in different ways in which the inside of the caliper is subsequently machined. Through that opening, which is not the assembly opening, only the tool itself gets into the cavity, that is, into the interior of the brake caliper. The tool holder, on the other hand, is moved in another way into a position relative to the position of the brake caliper that is suitable for the subsequent machining of the support surface. Only then is the tool holder equipped with the tool fed through the additional opening, so that the machining of the support surface can then begin.

Umgekehrt kann das Werkzeug nach Abschluss der Bearbeitung wieder durch dieselbe Öffnung, d. h. durch die zusätzliche Öffnung, aus dem Inneren des Bremssattels hinausgeführt werden.Conversely, the tool can be returned through the same opening, i.e. through the same opening. H. through the additional opening, out of the inside of the brake caliper.

Da das Bearbeitungswerkzeug, welches z. B. ein Fräskopf oder ein Bohrkopf sein kann, auf anderem Wege in den Bereich der Innenbearbeitung des Bremssattels gelangt als der zugehörige Werkzeughalter, ist der Bewegungsablauf, soweit dieser für die Fertigungspräzision relevant ist, einfach. Zusätzliche, mit zusätzlichem Lagerspiel verbundene Bewegungsoptionen entfallen, wodurch ein hochpräzises Bearbeiten der Abstützflächen innen im Bremssattel ermöglicht wird.Since the processing tool, which, for. B. can be a milling head or a drilling head, in other ways in the area of the inner machining of the brake caliper than the associated tool holder, the sequence of movements, insofar as this is relevant for manufacturing precision, is simple. Additional movement options associated with additional bearing play are eliminated, which enables high-precision machining of the support surfaces inside the brake caliper.

Die Öffnung, durch die das Werkzeug in den Hohlraum des Bremssattels geführt wird, stellt zwar eine zusätzliche Öffnung des Bremssattels dar. Sie kann sich jedoch an einem Ort befinden, zum Beispiel in der Sattelrückwand, wo eine solche Öffnung eine zweite Funktionalität ausüben kann und insbesondere eine Funktionalität, die für den späteren Betrieb der Bremse von Bedeutung ist. Insbesondere kann, wie dies an und für sich aus der DE 195 07 308 A1 bekannt ist, eine solche Öffnung dazu dienen, Elemente einer Rückstelleinrichtung aufnehmen. Denn Scheibenbremsen sind üblicherweise mit einer Nachstelleinrichtung versehen, welche das im Laufe der Zeit sich verändernde Lüftspiel der Bremse nachstellt bzw. nachjustiert. Sind die beiden Bremsbeläge der Scheibenbremse verschlissen, müssen sie ausgetauscht werden, und zugleich muss die Nachstelleinrichtung in ihre Ausgangsstellung zurückgestellt werden, was mittels der erwähnten Rückstelleinrichtung erfolgt.The opening through which the tool is guided into the cavity of the brake caliper represents an additional opening of the brake caliper. However, it can be located in a location, for example in the rear wall of the caliper, where such an opening can have a second functionality and in particular a functionality that is important for the later operation of the brake. In particular, how this can be done in and of itself DE 195 07 308 A1 is known to serve such an opening to accommodate elements of a reset device. Because disc brakes are usually with one Provide adjusting device, which adjusts or readjusted the air play of the brake, which changes over time. If the two brake linings of the disc brake are worn, they must be replaced, and at the same time the adjustment device must be returned to its starting position, which is done by means of the reset device mentioned.

Vorteilhafte Ausgestaltungen sind in den Unteransprüchen angegeben.Advantageous refinements are specified in the subclaims.

Gemäß einer Ausgestaltung des Verfahrens wird das Werkzeug zunächst durch die Öffnung geführt, und anschließend an den Werkzeughalter, der außerdem mit einem Drehantrieb für das Werkzeug versehen sein kann, übergeben, z. B. durch Kopplung mit dem Werkzeughalter.According to one embodiment of the method, the tool is first passed through the opening and then transferred to the tool holder, which can also be provided with a rotary drive for the tool, for. B. by coupling with the tool holder.

Vorzugsweise wird das Werkzeug durch eine Bewegung in Längsrichtung der Öffnung an den Werkzeughalter übergeben.The tool is preferably transferred to the tool holder by a movement in the longitudinal direction of the opening.

Gemäß einer weiteren Ausgestaltung des Verfahrens ragt der Werkzeughalter während der Übergabe des Werkzeugs zumindest teilweise in den Freiraum zwischen den beiden Sattelabschnitten hinein.According to a further embodiment of the method, the tool holder projects at least partially into the space between the two saddle sections during the transfer of the tool.

Eine weitere Ausgestaltung des Verfahrens ist gekennzeichnet durch die Schritte des Überführens des Werkzeugs zu dem Werkzeughalter und des Wegführens des Werkzeugs nach dessen Entkopplung von dem Werkzeughalter
Vorzugsweise ist bei der Durchführung der Bearbeitung der Bremssattel in einer Werkstückaufnahme fest positioniert, die relativ zu einem ortsfest angeordneten Maschinengestell in mindestens zwei Bewegungsachsen verfahrbar ist, und wobei die Werkstückaufnahme bei der Bearbeitung der Abstützfläche entlang einer dieser Bewegungsachsen bewegt wird.A further embodiment of the method is characterized by the steps of transferring the tool to the tool holder and moving the tool away after its decoupling from the tool holder
When carrying out the machining, the brake caliper is preferably fixedly positioned in a workpiece holder, which can be moved in at least two axes of movement relative to a stationary machine frame, and the workpiece holder is moved along one of these axes of movement during machining of the support surface.

Bei Einsatz einer solcherart beweglichen Werkstückaufnahme kann der Werkzeughalter selbst ortsfest und damit unbeweglich an dem Maschinengestell angeordnet sein. Er arbeitet auf diese Weise ohne Lagerspiel, was zu einer hohen Präzision bei der Bearbeitung der Abstützfläche führt.When using such a movable workpiece holder, the tool holder itself can be arranged in a stationary and thus immovable manner on the machine frame. In this way, it works without bearing play, which leads to high precision when machining the support surface.

Gemäß einer weiteren Ausgestaltung werden nacheinander zunächst eine erste Abstützfläche und dann eine zu dieser fluchtende, zweite Abstützfläche bearbeitet, wobei sich die Öffnung zwischen den Abstützflächen befindet. Durch diese Aufteilung der Abstützflächen besteht die Möglichkeit, einen ein zentrales Element der Zuspanneinrichtung bildenden Bremshebel gabelförmig zu gestalten, indem er sich mit einem ersten Schenkel gegen die eine, und mit einem zweiten Schenkel gegen die andere Abstützfläche abstützt.According to a further embodiment, first a first support surface and then a second support surface aligned with it are machined one after the other, whereby the opening is between the support surfaces. This division of the support surfaces makes it possible to design a brake lever, which forms a central element of the application device, in the form of a fork by being supported with one first leg against one and with a second leg against the other support surface.

Zur Bearbeitung der zwei voneinander getrennten Abstützflächen wird vorgeschlagen, dass nach dem Ankoppeln des Werkzeugs eine Relativbewegung des Werkzeugs zu dem Bremssattel in der folgenden Reihenfolge durchgeführt wird:

  1. a) ausgehend von einem Startpunkt gegenüberliegend der Öffnung zu einer Seite dieser Öffnung hin und innen längs der Sattelrückwand,
  2. b) zurück in den Bereich gegenüberliegend der Öffnung, und von dort zu der anderen Seite dieser Öffnung hin und wiederum innen längs der Sattelrückwand,
  3. c) zurück in den Bereich gegenüberliegend der Öffnung.
To machine the two separate support surfaces, it is proposed that after the tool is coupled, the tool moves relative to the brake caliper in the following order:
  1. a) starting from a starting point opposite the opening to one side of this opening and inside along the rear wall of the saddle,
  2. b) back into the area opposite the opening, and from there to the other side of this opening and again inside along the saddle wall,
  3. c) back to the area opposite the opening.

Gemäß einer weiteren Ausgestaltung des Verfahrens wird die Abstützfläche bzw. jede Abstützfläche H-förmig bearbeitet unter Ausbildung zweier breiterer Stützflächenabschnitte und einem zwischen diesen angeordneten, schmaleren Mittelabschnitt.According to a further embodiment of the method, the support surface or each support surface is machined in an H shape to form two wider support surface sections and a narrower central section arranged between them.

Mit einer weiteren Ausgestaltung wird vorgeschlagen, dass die Abstützfläche bzw. jede Abstützfläche als teilzylindrische Rinne bearbeitet wird. Vorzugsweise wird auf die so bearbeitete Abstützfläche eine als teilzylindrische Rinne gestaltete Lagerschale aufgesetzt, an deren Innenseite sich bei montierter Scheibenbremse der Bremshebel abstützen kann.In a further embodiment it is proposed that the support surface or each support surface is machined as a partially cylindrical groove. A bearing shell designed as a partially cylindrical groove is preferably placed on the support surface machined in this way, on the inside of which the brake lever can be supported when the disc brake is mounted.

Weitere Vorteile und Einzelheiten ergeben sich aus der nachfolgenden Beschreibung und unter Bezugnahme auf die beigefügten Zeichnungen. Darin zeigen:

Fig. 1
in einer Seitenansicht den Bremssattel und die Bremsscheibe einer Nutzfahrzeug-Scheibenbremse;
Fig. 2
einen Längsschnitt durch den in Fig. 1 mit II bezeichneten Abschnitt des Bremssattels;
Fig. 3
in einer perspektivischen Ansicht eine Abstützfläche innen an der Sattelrückwand des Bremssattels;
Fig. 4
die Abstützfläche einschließlich einer dort aufgesetzten Lagerschale;
Fig. 5
die rinnenförmig gestaltete Lagerschale in perspektivischer Einzeldarstellung;
Fig. 6
einen weiteren Längsschnitt durch die Sattelrückwand, die Abstützfläche und die darauf gesetzte Lagerschale;
Fign. 7a - d
verschiedene Schritte bei der Innenbearbeitung des Bremssattels mittels eines Fräswerkzeuges, wobei jeweils eine Werkzeugmaschine mit Werkstückhalter, daran positioniertem Bremssattel, einem ortsfesten Werkzeughalter und einer Einrichtung zur Übergabe des Fräswerkzeugs an den Werkzeughalter wiedergegeben ist.
Further advantages and details emerge from the following description and with reference to the accompanying drawings. In it show:
Fig. 1
in a side view the brake caliper and the brake disc of a commercial vehicle disc brake;
Fig. 2
a longitudinal section through the in Fig. 1 section designated by II of the brake caliper;
Fig. 3
in a perspective view a support surface on the inside of the caliper rear wall of the brake caliper;
Fig. 4
the support surface including a bearing shell placed there;
Fig. 5
the groove-shaped bearing shell in a perspective individual representation;
Fig. 6
a further longitudinal section through the rear wall of the saddle, the support surface and the bearing shell placed thereon;
Fig. 7a - d
Various steps in the internal machining of the brake caliper by means of a milling tool, wherein in each case a machine tool with a workpiece holder, brake caliper positioned thereon, a stationary tool holder and a device for transferring the milling tool to the tool holder are shown.

In Fig. 1 und Fig. 2 ist ein Bremssattel 1 einer Scheibenbremse wiedergegeben, wobei die Scheibenbremse hier von der Bauart einer druckluftbetätigten Nutzfahrzeugbremse des Schiebesattel- oder Schwimmsatteltyps ist. Der in einem einzigen Stück gegossene Bremssattel 1 setzt sich aus drei Abschnitten zusammen. Ein erster Sattelabschnitt 11, welcher sich bei montierter Bremse fahrzeuginnen befindet, ist in seinem Inneren mit einem über eine Montageöffnung 4 zugänglichen Hohlraum 7 versehen, welcher Platz für eine Bremszuspanneinrichtung bietet. Ein zweiter Sattelabschnitt 12, welcher sich bei montierter Bremse fahrzeugaußen befindet, ist auf der gegenüberliegenden Seite der Bremsscheibe 2 der Scheibenbremse angeordnet. Die beiden Sattelabschnitte 11, 12 sind durch einen Brückenabschnitt 13 miteinander verbunden, der die Bremsscheibe 2 überbrückt und dabei einen Freiraum 6 für zumindest einen Teil der Bremsscheibe 2 bereitstellt. Die Bremsscheibe 2 rotiert auf der Achse A.In 1 and 2 A brake caliper 1 of a disc brake is shown, the disc brake here being of the type of a compressed air-operated commercial vehicle brake of the sliding caliper or floating caliper type. The brake caliper 1 cast in a single piece is composed of three sections. A first caliper section 11, which is located inside the vehicle when the brake is mounted, is provided in its interior with a cavity 7 which is accessible via a mounting opening 4 and which offers space for a brake application device. A second caliper section 12, which is located outside the vehicle when the brake is mounted, is arranged on the opposite side of the brake disc 2 of the disc brake. The two caliper sections 11, 12 are connected to one another by a bridge section 13, which bridges the brake disc 2 and thereby provides a free space 6 for at least part of the brake disc 2. The brake disc 2 rotates on the axis A.

Der Bremssattel 1 ist einstückig insoweit, als die beiden Sattelabschnitte 11, 12 und der Brückenabschnitt 13 aus einem einzigen Teil bestehen, vorzugsweise durch gemeinsames Gießen in Eisenguss oder Stahlguss. Der Hohlraum 7 des ersten Sattelabschnitts 11 ist zu dem Freiraum 6 des Brückenabschnitts 13 hin offen. Diese Öffnung dient u. a. als Montageöffnung 4 und sie ist relativ groß, damit durch sie hindurch die Bremszuspanneinrichtung montiert werden kann. Die Öffnung bzw. Montageöffnung 4 wird, nach abgeschlossener Bremsenmontage, durch einen Deckel 5 verschlossen.The brake caliper 1 is in one piece insofar as the two caliper sections 11, 12 and the bridge section 13 consist of a single part, preferably by casting them together in cast iron or cast steel. The cavity 7 of the first saddle section 11 is open to the free space 6 of the bridge section 13. This opening serves u. a. as a mounting opening 4 and it is relatively large so that the brake application device can be mounted through it. The opening or assembly opening 4 is closed by a cover 5 after the brake assembly has been completed.

Nicht zeichnerisch wiedergegeben sind die beiden Bremsbeläge der Scheibenbremse. Ein erster Bremsbelag befindet sich in Fig. 1 rechts der Bremsscheibe 2. Dieser zuspannseitige Bremsbelag wird unmittelbar durch die in dem Hohlraum 7 des Sattelabschnitts 11 angeordnete Bremszuspanneinrichtung betätigt und so gegen die Bremsscheibe 2 gedrückt. Der zweite Bremsbelag ist in dem zweiten Sattelabschnitt 12 angeordnet und nimmt dort eine feste Position ein. Er ist der reaktionsseitige Bremsbelag.The two brake pads of the disc brake are not shown in the drawing. A first brake pad is in Fig. 1 to the right of brake disc 2. This on the tension side The brake pad is actuated directly by the brake application device arranged in the cavity 7 of the caliper section 11 and thus pressed against the brake disc 2. The second brake pad is arranged in the second caliper section 12 and takes a fixed position there. It is the brake lining on the reaction side.

Die Aufgabe der Bremszuspanneinrichtung ist die Verstärkung der durch ein Kraftglied erzeugten Bremskräfte und deren Übertragung in Zuspannrichtung Z, die sich parallel zur Achse A der Bremsscheibe 2 erstreckt. Bestandteile der Zuspanneinrichtung sind unter anderem ein in dem Sattelabschnitt 11 des Bremssattels 1 schwenkbar gelagerter Bremshebel 10 sowie ein in Richtung zu dem fahrzeuginneren, zuspannseitigen Bremsbelag arbeitendes Druckstück 8. Das Druckstück 8 hat die Gestalt einer sich quer zur Gehäuselängsrichtung erstreckenden Traverse. Auf der Mitte der Traverse 8 ist diese über ein Gewinde mit einem Druckstempel verbunden, der sich gegen den zuspannseitigen Bremsbelag der Scheibenbremse abstützt, und diesen so gegen die Bremsscheibe 2 beaufschlagen kann.The task of the brake application device is to amplify the braking forces generated by a force element and to transmit them in the application direction Z, which extends parallel to the axis A of the brake disc 2. Components of the application device include a brake lever 10 pivotably mounted in the caliper section 11 of the brake caliper 1 and a pressure piece 8 working in the direction of the vehicle-side brake lining on the application side. The pressure piece 8 has the shape of a cross-piece extending transversely to the longitudinal direction of the housing. In the middle of the crossbeam 8, this is connected via a thread to a pressure stamp, which is supported against the brake lining of the disc brake on the application side, and can thus act on the brake disc 2.

Der schwenkbare Bremshebel 10 ist gabelförmig gestaltet und besteht aus einem Hebelarm 14 und einer auf zwei Abschnitte aufgeteilten Zuspannwelle 15. Die Zuspannwelle 15 ist gegenüber einer Sattelrückwand 18 abgestützt, die den Hohlraum 7 bremsscheibenabgewandt verschließt. Diese Abstützung gegenüber der Sattelrückwand 18 des Bremssattels erfolgt mittels eines halbschalenförmig gestalteten, teilzylindrischen Schwenklagers 16.The pivotable brake lever 10 is fork-shaped and consists of a lever arm 14 and a clamping shaft 15 divided into two sections. The clamping shaft 15 is supported against a rear wall 18 of the caliper, which closes the cavity 7 away from the brake disk. This support with respect to the rear wall 18 of the brake caliper takes place by means of a semi-cylindrical, partially cylindrical pivot bearing 16.

Als Bestandteil des Schwenklagers 18 ist zwischen jedem der zwei Abschnitte der Zuspannwelle 15 und einer innen an der Sattelrückwand 18 angeformten Abstützfläche 20 jeweils eine Lagerschale 21 angeordnet. Ausschließlich an der Lagerschale 21, die ebenso wie die Abstützfläche 20 als eine teilzylindrische Rinne gestaltet ist, stützt sich die Zuspannwelle 15 des Bremshebels 10 ab. Dazu ist die Zuspannwelle 15 im Anlagebereich ebenfalls teilzylindrisch gestaltet mit einem Radius, der gleich ist dem Radius an der Innenseite der gebogenen Lagerschale 21.As part of the pivot bearing 18, a bearing shell 21 is arranged between each of the two sections of the application shaft 15 and a support surface 20 formed on the inside of the saddle rear wall 18. The application shaft 15 of the brake lever 10 is supported exclusively on the bearing shell 21, which, like the support surface 20, is designed as a partially cylindrical groove. For this purpose, the application shaft 15 is also partially cylindrical in the contact area with a radius that is equal to the radius on the inside of the curved bearing shell 21.

In die andere Richtung, also in Zuspannrichtung Z und damit zu den Bremsbelägen bzw. zu der Bremsscheibe 2 hin, ist die Zuspannwelle 15 über ein weiteres Schwenklager 17 schwenkbar gegen das Druckstück 8 abgestützt. Hierzu weist das Druckstück 8 einen Abstützbereich in Gestalt einer Halbschale auf. Das weitere Schwenklager 17 kann als Wälzlager oder als Gleitlager ausgebildet sein.In the other direction, ie in the application direction Z and thus towards the brake linings or the brake disc 2, the application shaft 15 is pivotally supported against the pressure piece 8 via a further pivot bearing 17. For this purpose, the pressure piece 8 has a support area in the form of a half-shell. The further pivot bearing 17 can be designed as a roller bearing or as a sliding bearing.

Zum Erzielen einer hohen Zuspannkraft ist die Zuspannwelle 15 exzentrisch gelagert. Denn das gegen die Lagerschale 21 und damit mittelbar gegen den Bremssattel 1 abgestützte Schwenklager 16 weist eine in der Höhe versetzt angeordnete Schwenkachse im Vergleich zu der Schwenkachse des zwischen der Zuspannwelle 15 und dem Druckstück 8 angeordneten, weiteren Schwenklagers 17 auf. Bei einem Verdrehen der exzentrisch konturierten Zuspannwelle 15 kommt es daher in Zuspannrichtung Z zu einer Vorwärtsbewegung des Druckstücks 8, wodurch die Bremse Bremskraft auf die Bremsbeläge ausübt.In order to achieve a high clamping force, the clamping shaft 15 is mounted eccentrically. This is because the pivot bearing 16, which is supported against the bearing shell 21 and thus indirectly against the brake caliper 1, has a pivot axis which is offset in height compared to the pivot axis of the further pivot bearing 17 arranged between the application shaft 15 and the pressure piece 8. When the eccentrically contoured application shaft 15 is rotated, the pressure piece 8 therefore moves forward in the application direction Z, as a result of which the brake exerts braking force on the brake pads.

Dem Verdrehen der Zuspannwelle 15 dient der daran einstückig ausgebildete Hebelarm 14. Dieser ist nahe seines freien Endes mit einem Abstützort versehen, gegen den das Kraftglied der Scheibenbremse arbeitet. Bei druckluftbetätigten Scheibenbremsen ist dieses Kraftglied ein pneumatischer Bremszylinder, welcher durch das Druckluftsystem des Fahrzeugs mit Druckluft versorgt wird.The one-piece lever arm 14 is used to turn the application shaft 15. Near its free end, this is provided with a support location against which the power element of the disc brake works. In the case of compressed air-actuated disc brakes, this force element is a pneumatic brake cylinder, which is supplied with compressed air by the compressed air system of the vehicle.

Der Bremshebel 10 ist insgesamt gabelförmig, da er sich, ausgehend von dem auf der Schwenkmittellinie angeordneten Hebelarm 14, in zwei Schenkel verzweigt. An dem ersten Schenkel befindet sich der erste Abschnitt der Zuspannwelle 15, und an dem zweiten Schenkel der zweite Abschnitt der Zuspannwelle 15. Zwischen diesen beiden Abschnitten weist der Bremshebel 10 einen Freiraum auf. Dieser sowie ferner das mit einer Gewindebohrung versehene Zentrum des Druckstücks 8 bieten ausreichend Platz für eine Nachstelleinrichtung, welche den im Laufe der Zeit auftretenden Bremsverschleiß kompensiert und das Lüftspiel der Bremse korrigiert. Bestandteile der Nachstelleinrichtung sind u. a. ein Antriebselement, ein das Lüftspiel der Bremse verringerndes Abtriebselement, eine Einwegekupplung sowie ein Überlastglied. Als Abtriebselement der Nachstelleinrichtung dient eine Spindel. Diese ist mit einem Außengewinde versehen, welches in die Gewindebohrung im Zentrum des Druckstücks 8 eingeschraubt ist. Die meisten Einzelteile der Nachstelleinrichtung sind auf einer Nachstellachse angeordnet. Die Nachstellachse befindet sich auf der Zuspannachse Z und erstreckt sich zugleich senkrecht zu jener Ebene E, in der sich die Bremsscheibe 2 erstreckt.The brake lever 10 is generally fork-shaped, since it branches off into two legs, starting from the lever arm 14 arranged on the pivot center line. The first section of the application shaft 15 is located on the first leg, and the second section of the application shaft 15 is located on the second leg. The brake lever 10 has a free space between these two sections. This, as well as the center of the pressure piece 8 provided with a threaded bore, offer sufficient space for an adjusting device which compensates for brake wear occurring over time and corrects the air play of the brake. Components of the adjusting device are u. a. a drive element, an output element that reduces the clearance of the brake, a one-way clutch and an overload element. A spindle serves as the output element of the adjusting device. This is provided with an external thread which is screwed into the threaded hole in the center of the pressure piece 8. Most of the individual parts of the adjusting device are arranged on an adjusting axis. The adjustment axis is located on the application axis Z and at the same time extends perpendicular to that plane E in which the brake disc 2 extends.

Da die Zuspannwelle 15 zweigeteilt mit zwei Wellenabschnitten ist, sind auch mindestens zwei Abstützflächen 20 und zwei Lagerschalen 21 für die Abstützung der Wellenabschnitte vorhanden. Von diesen befindet sich eine Abstützfläche 20 mit ihrer Lagerschale 21 auf einer Seite der Zuspannachse Z, und die andere Abstützfläche 20 mit ihrer Lagerschale auf der anderen, gegenüberliegenden Seite der Zuspannachse Z.Since the application shaft 15 is divided in two with two shaft sections, there are also at least two support surfaces 20 and two bearing shells 21 for supporting the shaft sections. Of these, there is a support surface 20 with its bearing shell 21 on one side of the application axis Z, and the other support surface 20 with its bearing shell on the other, opposite side of the application axis Z.

In der Mitte zwischen den zwei Abstützflächen 20 und vorzugsweise zugleich auf der Nachstellachse der Nachstelleinrichtung befindet sich in der Sattelrückwand 18 des Bremssattels eine Öffnung 25. Die Öffnung 25 ist vorzugsweise rund und vorzugsweise als Bohrung ausgebildet. Indem die Öffnung 25 in der Sattelrückwand 18 ausgebildet ist, bietet sie bei betriebsfertig montierter Bremse Platz für ein Rückstellelement einer Rückstelleinrichtung. Denn sind die Bremsbeläge der Scheibenbremse verschlissen, müssen sie ausgetauscht werden. Anschließend muss die Nachstelleinrichtung in ihre Ausgangsstellung zurückgestellt werden, was mittels der erwähnten Rückstelleinrichtung erfolgt. Das Rückstellelement dieser Rückstelleinrichtung befindet sich in der Öffnung 25 der Sattelrückwand 18 und ist, vorzugsweise bereits auf der Außenseite der Sattelrückwand 18, mit Schlüsselflächen versehen, an die sich zum Rückstellen der Bremse ein entsprechendes Werkzeug ansetzen lässt.In the middle between the two support surfaces 20 and preferably at the same time on the adjusting axis of the adjusting device, there is an opening 25 in the rear wall 18 of the brake caliper. The opening 25 is preferably round and preferably a bore. Since the opening 25 is formed in the rear wall 18 of the saddle, it offers space for a reset element of a reset device when the brake is ready for operation. Because if the brake pads of the disc brake are worn, they have to be replaced. The adjustment device must then be reset to its starting position, which is done by means of the reset device mentioned. The restoring element of this restoring device is located in the opening 25 of the rear wall 18 of the saddle and, preferably already on the outside of the rear wall 18 of the saddle, is provided with key surfaces to which a corresponding tool can be attached for resetting the brake.

Gemäß Fig. 3 sind die Abstützflächen 20, auf denen die Bremskraft der Scheibenbremse lastet, jeweils als eine teilzylindrisch gekrümmte Rinne oder Schale gestaltet. Die zwei Abstützflächen 20 sind in gegenseitiger Fluchtung angeordnet. Die gemeinsame Bezugsachse der Radien ihrer teilzylindrischen Krümmungskonturen verläuft parallel zu der Ebene E, in der sich die Bremsscheibe erstreckt.According to Fig. 3 the support surfaces 20, on which the braking force of the disc brake rests, are each designed as a partially cylindrical groove or shell. The two support surfaces 20 are arranged in mutual alignment. The common reference axis of the radii of their partially cylindrical curvature contours runs parallel to the plane E in which the brake disc extends.

Die Fig. 3 lässt ferner erkennen, dass sich jede Abstützfläche 20 an einem gegenüber der Sattelrückwand 18 nach innen vorstehenden, beim Gießen des Sattels angegossenen Plateau 26 befindet.The Fig. 3 can also be seen that each support surface 20 is located on a plateau 26 protruding inward from the saddle rear wall 18 when the saddle is cast.

Jede Abstützfläche 20 ist H-förmig bearbeitet und besteht aus zwei Stützflächenabschnitten 30 mit größerer Rinnenbreite und einem dazwischen angeordneten Mittelabschnitt 31 mit geringerer Rinnenbreite. Der schmalere Mittelabschnitt 31 ist bedingt durch zwei Einschnitte 32, 33, die das Plateau 26 aufgrund des Gießprozesses aufweist. In jeden Einschnitt 32, 33 ragt eine flügelförmige Lasche 34, 35 der Lagerschale 21 hinein.Each support surface 20 is machined in an H-shape and consists of two support surface sections 30 with a larger channel width and an intermediate section 31 with a smaller channel width arranged between them. The narrower central section 31 is caused by two incisions 32, 33, which the plateau 26 has due to the casting process. A wing-shaped tab 34, 35 of the bearing shell 21 projects into each incision 32, 33.

Jede Lagerschale 21 besteht aus einem ursprünglich flachen, durch Stanzen und Verformen hergestellten Metallblech. Die teilzylindrisch gekrümmte Außenseite 29 liegt flächig gegen die Abstützfläche 20 an, wobei der Radius des Teilzylinders derselbe ist.Each bearing shell 21 consists of an originally flat metal sheet produced by stamping and shaping. The partially cylindrical outside 29 lies flat against the supporting surface 20, the radius of the partial cylinder being the same.

Die Außenseite 29 der Lagerschale 21 erstreckt sich weiter in Umfangsrichtung, als der schmale Mittelabschnitt 31 der Abstützfläche 20. Auf diese Weise ist es der Lagerschale 21 möglich, in Umfangsrichtung auf der Abstützfläche 20 zu wandern. Diese Bewegungsmöglichkeit ist allerdings in beide Umfangsrichtungen begrenzt, indem die Endbereiche der Laschen 34, 35 dann gegen die angegossenen Einschnitte 32, 33 stoßen. Die Laschen 34, 35 dienen daher als Anschläge, um die Bewegungsmöglichkeit der Lagerschale 21 in Umfangsrichtung zu begrenzen.The outer side 29 of the bearing shell 21 extends further in the circumferential direction than the narrow central section 31 of the support surface 20. In this way, the bearing shell 21 is able to move in the circumferential direction on the support surface 20. However, this possibility of movement is limited in both circumferential directions by the End regions of the tabs 34, 35 then abut the molded incisions 32, 33. The tabs 34, 35 therefore serve as stops in order to limit the possibility of movement of the bearing shell 21 in the circumferential direction.

Ferner besteht die Möglichkeit, dass die Laschen 34, 35 auch die Längsbewegung der teilzylindrischen Lagerschalen 21 begrenzen, indem die Laschen 34, 35 in Achsrichtung der teilzylindrischen Lagerschale 21 schmaler sind als die angegossenen Einschnitte 32, 33.Furthermore, there is the possibility that the tabs 34, 35 also limit the longitudinal movement of the partially cylindrical bearing shells 21 by the tabs 34, 35 being narrower in the axial direction of the partially cylindrical bearing shell 21 than the cast-in cuts 32, 33.

Die beiden Abstützflächen 20 lassen sich in der geforderten Präzision nicht rein gießtechnisch herstellen. Vielmehr ist es erforderlich, durch ein spanabhebendes Werkzeug und/oder ein Schleifwerkzeug die Abstützflächen 20 mit ihrer exakten, teilzylindrischen Kontur zu versehen. Hierzu muss ein geeignetes Bearbeitungswerkzeug entlang der Abstützflächen 20 geführt werden. Dies kann zum Beispiel ein rotierendes Fräswerkzeug mit teilkreisförmigem Fräskopf sein. Allerdings schränkt die einstückige Bauart des Bremssattels 1 die Möglichkeiten ein, ein Bearbeitungswerkzeug in den Hohlraum 7 des Bremssattelgehäuses zu verbringen, um dort auf den Plateaus 26 die beiden Abstützflächen 20 zu bearbeiten.The two support surfaces 20 cannot be produced with the required precision purely by casting. Rather, it is necessary to provide the support surfaces 20 with their exact, partially cylindrical contour by means of a cutting tool and / or a grinding tool. For this purpose, a suitable processing tool must be guided along the support surfaces 20. For example, this can be a rotating milling tool with a part-circular milling head. However, the one-piece design of the brake caliper 1 limits the possibilities of placing a processing tool in the cavity 7 of the brake caliper housing in order to machine the two support surfaces 20 there on the plateaus 26.

Jedoch gelingt dies bei Anwendung des nachfolgend anhand der Figuren 7a - 7d beschriebenen Verfahrens zur Innenbearbeitung des Bremssattels.However, this succeeds when using the following on the basis of Figures 7a - 7d described method for machining the brake caliper.

Die Figuren 7a - 7d zeigen jeweils eine Werkzeugmaschine 50 zum Bearbeiten des Bremssattels 1 und insbesondere auch der Abstützflächen 20 sowie ggf. weiterer Innenflächen des Bremssattels 1. Die Werkzeugmaschine 50 verfügt, im Rahmen des hier beschriebenen Fertigungsverfahrens, über zumindest drei Hauptelemente:

  1. 1. Die Werkzeugmaschine 50 verfügt über eine Werkstückaufnahme, in der der Bremssattel 1 fest positionierbar ist, z. B. durch Einspannen des Bremssattels. Die Werkstückaufnahme ist relativ zu dem ortsfest angeordneten Maschinengestell 54 der Werkzeugmaschine 50 in mindestens zwei Bewegungsachsen x, y verfahrbar. Die Bewegungsachse x erstreckt sich in Zuspannrichtung Z des eingespannten Bremssattels. Die Achse y erstreckt sich rechtwinklig zu der Achse x und in Längs- bzw. Fluchtungsrichtung der beiden Abstützflächen 20 bzw. parallel zu dieser Längs- bzw. Fluchtungsrichtung. Vorzugsweise ist die Werkstückaufnahme auch noch längs einer dritten Achse z positionierbar, die senkrecht auf den beiden Achsen x, y steht.
  2. 2. Die Werkzeugmaschine 50 verfügt ferner über einen Werkzeughalter 52. Dieser ist hier ortsfest an dem Maschinengestell 54 der Werkzeugmaschine angeordnet. Der Werkzeughalter 52 ist zur präzisen Aufnahme und zum Rotationsantrieb des Bearbeitungswerkzeuges 55 eingerichtet. Das Werkzeug 55 ist hier ein Stirnkopffräser, kann aber auch ein Formschleifwerkzeug sein.
  3. 3. Die Werkzeugmaschine 50 verfügt ferner über einen Werkzeuggreifer 53. Der Werkzeuggreifer 53 ist, vorzugsweise mittels eines pneumatischen Antriebs, dazu ausgebildet, das Bearbeitungswerkzeug 55 aus seiner Warteposition heraus mittels einer Teleskopeinrichtung soweit an den Werkzeughalter 52 heran zu führen und an diesen zu übergeben, dass das Werkzeug 55 dann an dem Werkzeughalter 52 verriegelbar ist. Die Verriegelung erfolgt zum Beispiel durch Spannen des Werkzeugs 55 in dem Werkzeughalter 52. Nach erfolgter Werkzeugübergabe zieht sich der Werkzeuggreifer 53 mittels der Teleskopeinrichtung wieder in die Warteposition zurück. Ferner ist der Werkzeuggreifer 53 dazu ausgebildet, nach erfolgter Bearbeitung der Abstützflächen 20 das am Werkzeughalter 52 verriegelte Werkzeug zu ergreifen und, nach dessen Entriegelung, zurück in die Warteposition zu transportieren. In beiden Fällen führt der Werkzeuggreifer 53 eine ausschließlich geradlinige Bewegung zwischen Warteposition und Werkzeughalter 52 durch.
The Figures 7a - 7d each show a machine tool 50 for machining the brake caliper 1 and in particular also the support surfaces 20 and, if appropriate, further inner surfaces of the brake caliper 1. The machine tool 50 has, as part of the production method described here, at least three main elements:
  1. 1. The machine tool 50 has a workpiece holder in which the brake caliper 1 can be firmly positioned, for. B. by clamping the caliper. The workpiece holder can be moved in at least two movement axes x, y relative to the stationary machine frame 54 of the machine tool 50. The movement axis x extends in the application direction Z of the clamped brake caliper. The axis y extends at right angles to the axis x and in the longitudinal or alignment direction of the two support surfaces 20 or parallel to this longitudinal or alignment direction. Preferably, the workpiece holder can also be positioned along a third axis z, which is perpendicular to the two axes x, y.
  2. 2. The machine tool 50 also has a tool holder 52. This is arranged here in a stationary manner on the machine frame 54 of the machine tool. The tool holder 52 is set up for the precise holding and for the rotational drive of the machining tool 55. The tool 55 is a face milling cutter here, but can also be a form grinding tool.
  3. 3. The machine tool 50 also has a tool gripper 53. The tool gripper 53 is designed, preferably by means of a pneumatic drive, to move the machining tool 55 out of its waiting position by means of a telescopic device as far as possible to the tool holder 52 and to transfer it to the latter. that the tool 55 can then be locked on the tool holder 52. The locking takes place, for example, by clamping the tool 55 in the tool holder 52. After the tool has been handed over, the tool gripper 53 pulls back into the waiting position by means of the telescopic device. Furthermore, the tool gripper 53 is designed to grip the tool locked on the tool holder 52 after the machining of the support surfaces 20 and, after its unlocking, to transport it back to the waiting position. In both cases, the tool gripper 53 performs an exclusively linear movement between the waiting position and the tool holder 52.

Gemäß Fig. 7a wird der zuvor einstückig gegossene Bremssattel 1 in einer der in zwei oder drei Achsen beweglichen Werkstückaufnahme positioniert. Die Werkstückaufnahme stellt den Bremssattel 1 anschließend so zu, dass der an der Werkzeugmaschine 50 ortsfest angeordnete Werkzeughalter 52 in jenen Freiraum 6 im Brückenabschnitt 13 des Bremssattels gelangt, in den bei betriebsfertiger Bremse die Bremsscheibe 2 zumindest zum Teil hineinreicht. Diese Zustellung ist beendet, wenn sich die Werkzeugaufnahme des Werkzeughalters 52 vor oder bereits in der Öffnung 4 des Bremssattels 1 befindet. Dieser Zustand ist in Fig. 7a wiedergegeben.According to Fig. 7a the brake caliper 1, previously cast in one piece, is positioned in one of the workpiece receptacles movable in two or three axes. The workpiece holder then closes the brake caliper 1 in such a way that the tool holder 52, which is arranged in a stationary manner on the machine tool 50, reaches the free space 6 in the bridge section 13 of the brake caliper into which the brake disk 2 at least partially extends when the brake is ready for operation. This infeed is ended when the tool holder of the tool holder 52 is in front of or already in the opening 4 of the brake caliper 1. This state is in Fig. 7a reproduced.

Gemäß Fig. 7b erfolgt daraufhin die Aktivierung des Werkzeuggreifers 53, an dem das Werkzeug 55 vorläufig angeordnet ist. In einer geradlinigen Bewegung führt der Werkzeuggreifer 53 das Werkzeug 55 durch die rückseitige Öffnung 25 und durch den Hohlraum 7 des Bremssattels hindurch bis in die Werkzeugaufnahme des Werkzeughalters 52. Dann wird das Werkzeug 55 an dem Werkzeughalter 52 verriegelt, z. B. in dessen Spannfutter. Anschließend gibt der Werkzeuggreifer 53 das Werkzeug frei und fährt in seine Warteposition zurück. Dies ist in Fig. 7c illustriert. Das Werkzeug befindet sich jetzt zumindest überwiegend in dem Hohlraum 7 des Bremssattels, und der Werkzeughalter 52 befindet sich überwiegend in dem Freiraum 6 vor dem Hohlraum 7.According to Fig. 7b The tool gripper 53 is then activated, on which the tool 55 is provisionally arranged. In a straight line movement, the tool gripper 53 guides the tool 55 through the rear opening 25 and through the cavity 7 of the brake caliper into the tool holder of the tool holder 52. Then the tool 55 is locked on the tool holder 52, eg. B. in its chuck. The tool gripper 53 then releases the tool and returns to its waiting position. This is in Fig. 7c illustrated. The tool is now at least predominantly in the cavity 7 of the brake caliper, and the tool holder 52 is predominantly in the free space 6 in front of the cavity 7.

Nun erfolgt das Bearbeiten der beiden Abstützflächen 20 von dem Freiraum 6 her und durch die Öffnung 4 hindurch mittels des in dem Werkzeughalter 52 rotierenden Fräswerkzeugs 55. Die für die fortschreitende Bearbeitung erforderliche Relativbewegung in y-Richtung (Fig. 3) beruht ausschließlich auf der Bewegung des Werkstückhalters, da der Werkzeughalter 52 ortsfest und unbeweglich ist. Im Einzelnen werden dabei Relativbewegungen des Fräskopfes in Bezug auf die Sattelrückwand 18 in der folgenden Reihenfolge durchgeführt:

  1. a) ausgehend von einem Startpunkt gegenüberliegend der Öffnung 25 zu einer Seite dieser Öffnung 25 hin und innen längs der Sattelrückwand 18,
  2. b) zurück in den Bereich gegenüberliegend der Öffnung 25, und von dort zu der anderen Seite dieser Öffnung 25 hin und wiederum innen längs der Sattelrückwand 18,
  3. c) zurück in den Bereich gegenüberliegend der Öffnung 25.
Now the two support surfaces 20 are machined from the free space 6 and through the opening 4 by means of the milling tool 55 rotating in the tool holder 52. The relative movement in the y direction required for the progressive machining ( Fig. 3 ) is based exclusively on the movement of the workpiece holder, since the tool holder 52 is stationary and immovable. In detail, relative movements of the milling head with respect to the saddle rear wall 18 are carried out in the following order:
  1. a) starting from a starting point opposite the opening 25 to one side of this opening 25 and inside along the rear wall 18 of the saddle,
  2. b) back into the area opposite the opening 25, and from there to the other side of this opening 25 and again inside along the rear wall 18 of the saddle,
  3. c) back into the area opposite the opening 25.

Sodann fährt gemäß Fig. 7d der Werkzeuggreifer 35 wieder aus, durch die Öffnung 25 und den Hohlraum 7 des Bremssattels hindurch bis an das Werkzeug 55, und ergreift dieses. Zugleich oder anschließend gibt das Spannfutter des Werkzeughalters 52 das Werkzeug frei. Daraufhin fährt der Werkzeuggreifer 53 mit dem Werkzeug 55 wieder in die Warteposition zurückfährt.Then drives according to Fig. 7d the tool gripper 35 out again, through the opening 25 and the cavity 7 of the brake caliper up to the tool 55, and grips it. At the same time or subsequently, the chuck of the tool holder 52 releases the tool. The tool gripper 53 then moves the tool 55 back into the waiting position.

Das Bearbeiten und vorzugsweise Fräsen der Abstützflächen 20 ist damit beendet, und es kann entweder in derselben Einspannung des Bremssattels 1 oder in einer anderen Einspannung oder in einer anderen Werkzeugmaschine eine weitere innere oder auch äußere Bearbeitung des Bremssattels 1 beginnen.The machining and preferably milling of the support surfaces 20 is thus ended, and further internal or external machining of the brake caliper 1 can begin either in the same clamping of the brake caliper 1 or in a different clamping or in another machine tool.

Die Schritte des Verfahrens können selbstverständlich auch erreicht werden, wenn die Werkstückaufnahme in der Werkzeugmaschine unbeweglich fixiert ist und sich der Werkzeughalter bewegt. Auch die Kombination einer Bewegung von Werkzeug- und Werkstückhalter ist denkbar.The steps of the method can of course also be achieved if the workpiece holder is immovably fixed in the machine tool and the tool holder moves. The combination of a movement of the tool and workpiece holder is also conceivable.

BezugszeichenlisteReference list

11
BremssattelBrake caliper
22nd
BremsscheibeBrake disc
44th
Öffnung, MontageöffnungOpening, assembly opening
55
Deckelcover
66
Freiraumfree space
77
Hohlraumcavity
88th
Druckstück, TraverseThrust piece, traverse
1010th
BremshebelBrake lever
1111
SattelabschnittSaddle section
1212th
SattelabschnittSaddle section
1313
BrückenabschnittBridge section
1414
HebelarmLever arm
1515
ZuspannwelleApplication shaft
1616
SchwenklagerSwivel bearing
1717th
SchwenklagerSwivel bearing
1818th
SattelrückwandRear saddle
2020th
AbstützflächeSupport surface
2121
LagerschaleBearing shell
2525th
Öffnungopening
2626
Plateauplateau
2929
AußenseiteOutside
3030th
StützflächenabschnittSupport surface section
3131
MittelabschnittMiddle section
3232
Einschnittincision
3333
Einschnittincision
3434
LascheTab
3535
LascheTab
5050
WerkzeugmaschineMachine tool
5252
WerkzeughalterTool holder
5353
WerkzeuggreiferTool gripper
5454
MaschinengestellMachine frame
5555
WerkzeugTool
AA
Drehachse der BremsscheibeAxis of rotation of the brake disc
EE
Ebene der BremsscheibeLevel of the brake disc
xx
Achseaxis
yy
Achseaxis
ze.g.
Achseaxis
ZZ.
Zuspannrichtung, NachstellachseApplication direction, adjustment axis

Claims (16)

  1. Method for machining the interior of a brake caliper (1) of a disc brake, on which are formed:
    - a first caliper portion (11) on the one side of the brake disc of the disc brake,
    - a second caliper portion (12) on the other side of the brake disc, and
    - a bridge portion (13) connecting the caliper portions (11, 12) and providing a free space (6) for at least a part of the brake disc,
    wherein at least one of the caliper portions is provided with a cavity (7) for receiving a brake application device, which cavity (7) comprises a mounting opening (4) towards the free space (6) and extends in the opposite direction as far as a caliper rear wall (18), on the inner side of which at least one support surface (20) is formed for the forces acting during the brake application, wherein the machining of the support surface (20) is carried out from the free space (6) and through the mounting opening (4), and for this purpose, a tool (55) is brought into the cavity (7) from outside the brake caliper (1), characterized in that the tool (55) is guided into the cavity (7) through an opening (25) other than the mounting opening (4).
  2. Method according to Claim 1, characterized in that after completing the machining, the tool (55) is withdrawn again from the cavity (7) through the opening (25).
  3. Method according to Claim 1 or 2, characterized in that the opening (25) through which the tool (55) is guided is located in the caliper rear wall (18) .
  4. Method according to any of Claims 1 - 3, characterized in that the tool (55) which is guided through the opening (25) is then transferred to a tool holder (52).
  5. Method according to Claim 4, characterized in that the tool holder (52) is provided with a rotary drive for the tool (55).
  6. Method according to Claim 4 or 5, characterized in that the tool (55) is transferred to the tool holder (52) by a movement in the longitudinal direction of the opening (25).
  7. Method according to any of Claims 4 - 6, characterized in that during transfer of the tool (55), the tool holder (52) protrudes at least partially into the free space (6) between the caliper portions (11, 12).
  8. Method according to any of Claims 4 - 7, characterized by the steps of transferring the tool (55) to the tool holder (52) and withdrawing the tool (55) after it has been decoupled from the tool holder (52).
  9. Method according to any of Claims 4 - 8, characterized in that the brake caliper (1) is fixedly positioned in a workpiece holder which can be moved in at least two movement axes (x, y) relative to a stationary machine frame and is moved along one of these machining axes during machining of the support surface (20).
  10. Method according to Claim 9, characterized in that the tool holder (52) is arranged so as to be stationary on the machine frame.
  11. Method according to any of Claims 3 - 10, characterized in that successively initially a first support surface situated on the one side of the opening (25) and then a second support surface aligned thereto and situated on the other side of the opening (25) are machined.
  12. Method according to Claim 11, characterized in that after coupling, a relative movement of the tool (55) relative to the brake caliper (1) takes place in the following order:
    a) starting from a starting point opposite the opening (25), towards one side of this opening (25) and along the inside of the caliper rear wall (18),
    b) back into the region opposite the opening (25), and from there towards the other side of this opening (25) and again along the inside of the caliper rear wall (18),
    c) back into the region opposite the opening (25).
  13. Method according to any of the preceding claims, characterized in that the support surface (20) is machined into an H shape forming two wider support surface portions (30) and arranged in between these a narrower middle portion (31).
  14. Method according to any of the preceding claims, characterized in that the support surface (20) is machined as a partially cylindrical channel.
  15. Method according to Claim 14, characterized in that a bearing shell (21) formed as a partially cylindrical channel is placed on the machined support surface (20).
  16. Method according to any of Claims 4 - 15, characterized in that the tool (55) is transferred to the tool holder (52) by means of a tool gripper (53) in a rectilinear movement.
EP17811185.2A 2016-08-16 2017-08-08 Method for machining the interior of a brake caliper of a disc brake Active EP3500769B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102016115176.9A DE102016115176A1 (en) 2016-08-16 2016-08-16 Method for internal machining of a brake caliper of a disc brake
PCT/DE2017/100668 WO2018033178A1 (en) 2016-08-16 2017-08-08 Method for machining the interior of a brake caliper of a disc brake

Publications (3)

Publication Number Publication Date
EP3500769A1 EP3500769A1 (en) 2019-06-26
EP3500769B1 true EP3500769B1 (en) 2020-04-01
EP3500769B2 EP3500769B2 (en) 2023-08-30

Family

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Application Number Title Priority Date Filing Date
EP17811185.2A Active EP3500769B2 (en) 2016-08-16 2017-08-08 Method for machining the interior of a brake caliper of a disc brake

Country Status (5)

Country Link
US (1) US10682711B2 (en)
EP (1) EP3500769B2 (en)
CN (1) CN109715970B (en)
DE (1) DE102016115176A1 (en)
WO (1) WO2018033178A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018122008A1 (en) * 2018-09-10 2020-03-12 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Brake caliper of a disc brake and disc brake
CN115351555B (en) * 2022-09-05 2023-03-28 安徽艾德河汽车部件有限公司 Processing equipment of brake disc grooving mold processing with anti-collision mechanism

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EP1160480A2 (en) 2000-05-31 2001-12-05 Haldex Brake Products AB Caliper and a method for assembly of a brake mechanism in said caliper
EP1881472A1 (en) 2006-07-18 2008-01-23 Lucas Varity s.r.o. Fastening device for attaching a brand mark plate to a disc brake caliper
DE102007001960A1 (en) 2007-01-13 2008-07-17 Bpw Bergische Achsen Kg disc brake
EP2304261B1 (en) 2008-07-31 2016-03-09 Wabco Radbremsen GmbH Method for producing a brake caliper, machining tool for carrying out the method, brake caliper produced using the method, and disk brake having a caliper of said type
DE102008036033A1 (en) 2008-08-01 2010-02-11 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Pneumatically actuated disc brake
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Also Published As

Publication number Publication date
DE102016115176A1 (en) 2018-02-22
US10682711B2 (en) 2020-06-16
EP3500769A1 (en) 2019-06-26
CN109715970A (en) 2019-05-03
CN109715970B (en) 2021-05-07
US20190210121A1 (en) 2019-07-11
WO2018033178A1 (en) 2018-02-22
EP3500769B2 (en) 2023-08-30

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